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Early Detection of Faulty Contactors in Solar Inverters

By Case Study

IDENTIFIED FAILURES

INDUSTRY

  • Renewable Energy

ASSET

  • Inverter

PROBLEM

  • Contactors

AVOIDED

  • Unplanned Stoppage
  • Loss of production

THE ROLE OF PV plants IN ENERGY PRODUCTION

Photovoltaic (PV) plants are at the forefront of the global transition to renewable energy, offering clean, scalable, and increasingly cost-effective electricity generation. With the deployment of large-scale solar farms, solar energy plays a vital role in diversifying the energy matrix and reducing greenhouse gas emissions. To ensure consistent energy output, the reliability of critical components such as inverters, transformers, and power electronics is fundamental.

IMPORTANCE OF CONTACTORS

Contactors are key components in managing harmonic filtering and reactive power compensation in PV inverters. Their proper functioning directly impacts inverter performance, safety, and energy quality. Failures in these contactors, especially when undetected, can trigger abnormal behavior in the transformer, operational noise, or complete shutdowns, undermining system reliability.

CONSEQUENCES OF THE FAILURE OF THE CONTACTORS

Failure of contactors in solar plants can lead to unexpected system shutdowns, interrupting power generation and causing extended periods of downtime. This not only results in immediate energy production losses but may also compromise the stability of connected components such as transformers or inverters. In critical scenarios, repeated failures can accelerate equipment degradation and pose safety risks. Moreover, if replacement parts are not readily available, recovery can be delayed significantly, highlighting the importance of preventive diagnostics, inventory planning, and condition based monitoring to ensure operational continuity and minimize revenue impact.

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    Cable Junction Anomaly in Wind Turbines

    By Case Study

    IDENTIFIED FAILURES

    INDUSTRY

    • Renewable Energy

    ASSET

    • Wind Turbine

    PROBLEM

    • Cable Joint damage

    AVOIDED

    • Unplanned Stoppage
    • Loss of production

    THE ROLE OF WIND TURBINES IN ENERGY PRODUCTION

    Wind turbines are essential in the global transition to sustainable energy. By converting wind into electricity, they offer a clean, renewable alternative to fossil fuels with no direct carbon emissions. Advances in turbine technology have made wind power more efficient and affordable, helping decarbonize the energy sector. As countries aim to reduce fuel imports and diversify energy sources, wind energy strengthens energy security, supports economic stability, and promotes environmental sustainability.

    IMPORTANCE OF CABLES CONNECTING THE WIND TURBINE TO THE SUBSTATION

    Cables linking wind turbines to substations are crucial for transporting generated electricity to the grid. These components must endure environmental stress, mechanical loads, and voltage fluctuations. Their quality and condition affect energy efficiency, operational safety, and overall system reliability. Proper cable design, insulation and maintenance help to avoid faults and ensure long-term performance of wind energy systems.

    CONSEQUENCES OF CABLE FAILURES

    Cable failures can disrupt power transmission, causing energy losses and financial setbacks. These failures are especially costly due to the complexity of repairs and limited access. Persistent or unnoticed damage can lead to overheating, system faults and further component failures, reducing lifespan and safety. Extended downtimes may also affect grid reliability and investor trust, underscoring the importance of durable cables, continuous monitoring, and preventive maintenance.

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      Rubber Coupling and Sprocket Failures in Cement Mill Elevator

      By Case Study

      IDENTIFIED FAILURES

      INDUSTRY

      Cement

      ASSET

      Silos Feeding Elevator

      PROBLEM

      Damaged rubber coupling
      and worn sprockets

      AVOIDED

      Unplanned Stoppage

      Loss of production

      IMPORTANCE OF THE SILOS FEEDING ELEVATOR IN CEMENT PRODUCTION

      The Silos Feeding Elevator plays a crucial role in the cement production process, particularly in the stage where raw materials such as clinker, gypsum, and additives are transported to the mill. It ensures´the consistent and efficient delivery of materials to the cement mill, which directly influences the overall production efficiency, material handling, and energy consumption.

       

      IDEAL FUNCTIONING OF THE SILOS FEEDING ELEVATOR

      Under optimal conditions, the Silos Feeding Elevator operates with uniform speed and precise material feeding, ensuring a continuous and smooth supply of materials to the cement mill. This helps in maintaining a steady grinding process and contributes to the consistent quality of the cement.
      The elevator system should have minimal mechanical stress, with effective lubrication, proper alignment, and condition monitoring to avoid irregular wear on the components. Regular maintenance and condition monitoring are essential to ensure uninterrupted operation and prevent material flow disruptions, which can impact the  efficiency of the entire cement production line.

       

      MECHANICAL TRANSMISSION FAILURES: DAMAGED RUBBER COUPLING AND WORN SPROCKETS

      The detection of a damaged rubber coupling and worn sprockets highlighted mechanical transmission vulnerabilities. The rubber coupling, which connects rotating shafts while damping vibrations and compensating for misalignments, had deteriorated, potentially due to misalignment, overload, or material fatigue, resulting in impaired torque transmission and increased mechanical stress.
      Simultaneously, the sprockets, essential for driving chain-based power transmission, showed signs of tooth wear and deformation. This condition can cause chain slippage, irregular motion, and excessive vibration. The combined degradation of these components compromises the efficiency, reliability and longevity of the cement mill’s drive system, underlining the necessity of timely inspection and replacement to prevent unplanned failures and ensure stable mill operation.

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        Kiln Crank Effect

        By Case Study

        IDENTIFIED FAILURES

        INDUSTRY

        Cement

        ASSET

        Kiln

        PROBLEM

        Crank Effect

        AVOIDED

        Unplanned Stoppage

        Kiln permanent deformation

        The rotary kiln is essential in cement production, transforming raw materials into clinker through high-temperature processing. Ideally, it rotates smoothly to ensure uniform heat distribution, which is crucial for efficient chemical reactions and high-quality clinker production.
        A major issue affecting kiln operation is the kiln crank effect, caused by uneven thermal expansion. This leads to deformation, irregular rotation, and mechanical stress on critical components, increasing wear, power consumption, and potential structural damage. Proper maintenance and temperature control are key to preventing these issues.

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          CIGRE 2024 Paris

          By News

          The Biennial Session is held in Paris, France in even number years. It is the number one global power system event in the world, bringing together some 9000 power industry participants from over 100 countries, including 3600 international experts and other decision-makers. This is a unique weeklong interactive opportunity. Over 160 working meetings, over 30 Study Committee sessions and 800+ technical papers spanning the end-to-end power system.

          Once again we are be heading to CIGRE in the day 25 to 30 of August. You can visit us on the Stand Nr. 1P40.

          Do you want to know more about this? Meet Us there.

           

          #innovative #accurate #simple #non-invasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

          Data Engineer

          By Job Offer

          Company description

          Engineering company specialized in the development of innovative products for monitoring industrial equipment. Today, the company has large industrial players in the Iberian Peninsula as clients and intends to grow to become a world reference in offering technological solutions for an industry.

          Description of functions

          The company searches for a collaborator based in Engineering for its ML/AI department, with the personnel taste for data analysis and algorithms development. This person will work directly with R&D and Administration team in a business role with great growth potential.

          Main functions to develop:

          • Data analysis
          • ML/AI
          • Development of new technological algorithms

          Main requirements for a role:

          • Engineering knowledge base (electrical preferred)
          • Strong knowledge of phyton programming
          • High communication skills (oral and written) and auto-critical ability
          • Autonomy and results orientation
          • Proficiency in English

          Essential requirements:

          • Knowledge of rotating machines and transformers
          • Pleasure to deal with technological products and technical engineering complexity

          Valuable Aspects:

          • Knowledge of Labview
          • Knowledge of Matlab

          Remuneration

          Negotiation of agreed goals and demonstrated experience.

          This could be your opportunity
          Send us your application to geral@enging.pt

          Backend Dev Engineer

          By Job Offer

          Does new technology excite you?
          Enging – Make Solutions should be your workplace!

          Started in Portugal in 2011, Engineering company focused on developing innovative and disruptive products for real time monitoring of electric machines. Today has as client’s major industrial players and intends to grow to become a world reference in offering predictive maintenance technological solutions.

          The company is looking for a BackEnd Dev Engineer for the industry sector to develop its web platform. This person will work directly with the R&D team and work to increase the company’s great growth potential.

          Main functions to develop:
          • Support in the implementation of the company’s operational objectives
          • Definition and implementation of new developments

          Main requirements for the role:
          • Engineering knowledge base (informatics preferred)
          • Experience in similar roles
          • High communication and critical capacity
          • Autonomy and results orientation
          • Proficiency in English
          • A clear understanding of Object Oriented Programming (OOP)
          • Create testable code and prioritize testing

          Essential requirements:
          • 2+ years of Javascript experience (TypeScript, React.js, Node.js, MongoDB stack)
          • API design and development
          • User interface development
          • Experience in microservices architectures
          • Experience in database design and programming (MongoDB preferred)
          • Knowledge of object storage (Preferred MinIO)
          • Knowledge of message brokering tools (RabbitMQ preferred)
          • Knowledge of test frameworks (jest, jasmine, karma, mocha, etc.)
          • Experience with version control and CI/CD software
          • Experience in deploying applications on local and/or external networks
          • Experience with containerized applications (Docker)

          Valuable Aspects:
          • Full-Stack Development
          • Semantic documents in HTML5 and CSS
          • Kubernetes
          • Virtual Machines & Server Management
          • Computer Networks
          • Linux Management
          • Management of distributed database architectures (MongoDB)
          • Backup Management (DBs & VM’s)

          This could be your opportunity
          Send us your application to geral@enging.pt

          World WaterTech Summit North America 2021

          By News

          World Water Tech has established itself as a meeting place for international stakeholders focused on advancing the commercialisation of advanced water and wastewater solutions in London and North America.

          It is with great pleasure that we announce our virtual presence at the World Water Tech North America Summit.

          Do you want to know more about this?

          Meet Us there.

           

          #insideenging #worldwatertechnorthamerica #innovative #accurate #simple #noninvasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

          CIRED 2021 – 26th International Conference and Exhibition on Electricity Distribution

          By News

          The 26th International Conference and Exhibition on Electricity Distribution – CIRED (International Conference and Exhibition on Electricity Distribution) will be held virtually this year, and will start on September 20th, providing all interested parties the opportunity to participate in this event.
          CIRED 2021 gives all participants an opportunity to hear about new research, ideas and initiatives; and interact with hundreds of key decision-makers in the electricity distribution field.

          It is with great pleasure that we announce our virtual presence on CIRED. We will also have the opportunity to present a paper developed by our R&D director, Jorge Estima.

          Do you want to know more about this? Meet Us there.

           

          #insideenging #CIRED #innovative #accurate #simple #non-invasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

          Business Development Manager

          By Job Offer

          Does new technology excite you?
          Enging – Make Solutions should be your workplace!

          Started in Portugal in 2011, Engineering company focused on developing innovative and
          disruptive products for real time monitoring of electric machines. Today has as client’s major
          industrial players in the Energy sector and intends to grow to become a world reference in
          offering predictive maintenance technological solutions.

          The company is looking for a Business Development Manager for renewable sector with
          proven track record in selling business solutions to large utilities customers. This person will
          work directly with the management team and share the leadership of a key business function
          with great growth potential.

           

          KEY RESPONSIBILITIES

          • Support the company’s business development strategy
          • Customer acquiring and management
          • Identifying, qualifying, and managing multiple opportunities at once
          • Definition, management and negotiation of commercial contracts with customers, distributors or other business partners in its markets
          • Identification of new growth opportunities
          • Planning, preparing and giving presentations and capability demonstrations
          • Support the implementation of new marketing initiatives

          QUALIFICATIONS, SKILLS AND EXPERIENCE

          • At least 2 years’ experience in sales to b2b customers
          • Degree on Engineering or Management
          • Experience with large utilities companies (Preferential)
          • Consultative style with good negotiation skills
          • Autonomy and results orientation
          • Knowledge of Digital Transformation
          • Excellent written and spoken English and Spanish skills
          • Full Driving license
          • Current and valid passport

          BENEFITS

          • Flexible working hour model and workplace
          • Health insurance
          • Training
          • Company’s car and electronic means
          • Fixed component and a variable component money package connected to goals

           

          This could be your opportunity

          Send us your application to geral@enging.pt